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Tolliver Fundamentals of Distillation Column Control1 PDF
Tolliver Fundamentals of Distillation Column Control1 PDF
Tolliver Fundamentals of Distillation Column Control1 PDF
by Terry Tolliver
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
ISA Automation Week 2011
PRESENTER – Terry Tolliver
2
DISTILLATION CONTROL TOPICS
• Levels of control
• Classification and pairing of variables
• Control objectives and constraints
• Dynamic responses
• Material and energy balances
• Separation
• Pressure control
• Material balance control
• Temperature control
• References
3
DISTILLATION CONTROL
BASIC
–Inventory Control
–Composition Control
SUBOPTIMIZING
–Feedforward Control
–Two Point Composition Control
OPTIMIZING
–Floating Pressure
–Maximum Profit
4
CLASSIFICATION and PAIRING of VARIABLES
CONTROLLED P
VARIABLES
La Y
distillate composition Y
bottom composition X
accumulator level La
sump level Ls
column pressure
P
Ls X
5
CLASSIFICATION and PAIRING of VARIABLES
MANIPULATED Qc
VARIABLES
distillate flow D
B R D
bottom flow
reflux flow R
reboiler duty Qr
condenser duty Qc
Qr
6
CLASSIFICATION and PAIRING of VARIABLES
DISTURBANCE
VARIABLES W
feed flow F F
feed composition Z
Z
feed temperature q
reboiler heat supply q
S
condenser cooling
W
supply and weather
7
CLASSIFICATION and PAIRING of VARIABLES
8
CONTROL OBJECTIVES
RECOVERY
9
COLUMN CONSTRAINTS
Reboiler
Flood
Condenser
Boilup rate
Weep
Vessel Limit
Column Pressure
10
COLUMN INTERNALS
TRAYS
– SIEVE TRAYS
– VALVE TRAYS
– BUBBLE CAP TRAYS
– DUAL FLOW TRAYS
PACKING
– RANDOM PACKING
– STRUCTURED PACKING
– LIQUID & VAPOR DISTRIBUTORS
11
COLUMN DYNAMICS
time
12
MATERIAL & ENERGY BALANCES
MATERIAL BALANCE
F = D+ B
D/F = (z-x)/(y-x)
zF = yD + xB
ENERGY BALANCE
hF + Qreb = hD + hB + Qcond
13
SEPARATION
TOTAL REFLUX
αn = [y(1-x)]/[x(1-y)]
NORMAL OPERATION
S = f (α, N, N , V/F, z, E)
F
14
MATERIAL BALANCE and SEPARATION EFFECTS
1.0
Increasing S y
Light Key Mole Fraction
X
Increasing S
0
0 D/F 1.0
15
MATERIAL BALANCE CONTROL
FC FC
LC
FC
TC
FC
LC
FC
16
SEPARATION CONTROL
FC FC
LC
FC
TC
NOT
RECOMMENDED
FC
LC
FC
17
PRESSURE CONTROL
VENT
PI
FC FC
LC
18
CONDENSER DUTY
Tp
Qcond = UA(Tp-Tc)
COOLANT
Tc
VENT
CONDENSATE
19
“BLOCK & BLEED” PRESSURE CONTROL
INERTS
BLEED VALVE
VACUUM SOURCE
BLOCK VALVE
PC
FC FC
LC
20
MATERIAL BALANCE CONTROL - TYPE 1
FC FC
LC
FC
TC
FC
LC
FC
21
MATERIAL BALANCE CONTROL - TYPE 2
FC FC
LC
FC
TC
FC
LC
FC
22
MATERIAL BALANCE CONTROL - TYPE 3
FC FC
LC
FC
TC
FC
LC
FC
23
MATERIAL BALANCE CONTROL - TYPE 4
FC FC
LC
FC
TC
response
FC
LC
time
FC
24
PROCESS SIMULATION
STEADY STATE
• PARAMETRIC CASES
• CONTROL STAGE LOCATION
• SENSITIVITY ANALYSIS
• DISTURBANCE ANALYSIS
DYNAMIC
• STUDY CONTROL RESPONSE
• STARTUP AND SHUTDOWN
25
CONTROL STAGE LOCATION
18
17
16
15
14
13
12
11
Stage Number
10
9 +1%D/F
8
4 -1%D/F
3
0
70.0 75.0 80.0 85.0 90.0 95.0 100.0 105.0 110.0 115.0 120.0
Tem perature, DegC
26
TEMPERATURE SENSITIVITY
DISTILLATE PRODUCT
COMPOSITION, wt%
BOTTOM PRODUCT
27
DISTURBANCE ANALYSIS
17
16
15
14
13
12
11
10
Tray Number
0
-5.0 -4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0
Delta Tem perature, DegC
28
REFERENCES
29
REFERENCES
30